Abstract: Continuous hot dip aluminum coated ferritic chromium alloy steel strip. Strip is cleaned by heating to a temperature no greater than about 650.degree. C. in a direct fired furnace. The cleaned strip is further heated in a protective atmosphere containing at least 95% by volume hydrogen, cooled in the protective hydrogen atmosphere to near or slightly above the melting point of an aluminum coating metal, and passed into a bath of the aluminum coating metal. The low direct fired furnace cleaning temperature and hydrogen protective atmosphere provides good wetting of a chromium alloy steel surface to prevent uncoated areas or pin holes in the aluminum coated layer.

Abstract: An apparatus and method for measuring and machining the roundness and concentricity of an outer surface of a roll having oppositely disposed ends spaced along a longitudinal axis. The apparatus includes a plurality of spaced roll supports for rotatably supporting the outer surface, and one or more drive wheels to rotate the roll about its longitudinal axis. An axial strut is provided for limiting the axial movement of the roll during rotation, and a pair of locators are individually mounted adjacent each of the ends of the roll and establish a reference line along the roll. A plurality of displacement monitoring devices using lasers simultaneously measure variations in the contour of the outer surface and movement of the reference line as the roll is rotated. The apparatus is further designed to determine the true axis of rotation of the roll, whereby a profile of the roll can be obtained by comparing roundness measurements taken at any point along the longitudinal axis to the true axis of rotation.

Abstract: Steel sheet coated with a nontoxic, relatively insoluble, inorganic, corrosion resistant coating. A silicate coating is formed on a steel sheet by rinsing the sheet for at least 30 seconds in an alkaline aqueous solution containing 0.005 M silicate, 0.005 M metal salt and having a temperature of at least 25.degree. C. The sheet is dried to form an adherent silicate coating having a thickness of at least 2 nm prior to being treated with an aqueous solution containing 0.5-5 vol.-% silane. If the sheet is painted, the silane film forms an adherent bond between the paint and the silicate coating. A silane treated silicate coating minimizes red rusting on terne coated steel by sealing pin holes. A silane treated silicate coating also provides good corrosion protection and paint adherence on cold-rolled or galvanized steel.

Abstract: Caustic dezincing galvanized steel scrap. A dezincing plant includes a plurality of tanks interconnected in series with steel scrap sequentially being moved through each of the tanks. The tanks contain a caustic leaching solution including an oxidant with the leaching solution being circulated through each of the tanks in a direction opposite to the movement of the scrap. Fresh scrap initially is exposed to a partially depleted leaching solution with the oxidant concentration of the leaching solution increasing as the scrap moves through the series of tanks. Leaching solution depleted of its oxidant is transferred to an electrolytic cell where zinc is removed and plated as metallic zinc powder onto a cathode. The leaching solution is recycled by removing zinc. The chemistry of the leaching solution is controlled so that sufficient free caustic is present to prevent passivating zinc coating on the scrap.

Abstract: A device for systematic sampling coarse material sliding down an inclined chute. A bottom portion of the chute is removed and replaced by a sampling device mounted below the chute opening. The sampling device includes a drum for receiving the sample, a gate mounted to the bottom of the chute for rotation between open and closed positions and a motor for rotating the drum. The outer surface of the drum is provided with an opening. The drum is rotated until the drum opening is aligned with the chute opening causing the gate to be rotated to its open position. Material is diverted from the chute into the drum. After the sample is obtained, rotation of the drum is continued until the gate is closed so that the material continues to slide down the chute without passing into the drum.

Abstract: A non-aging, cold reduced, recrystallization annealed, low manganese, aluminum killed steel having an r.sub.m value greater than 1.8 produced from a slab having a reduced hot rolling temperature. A slab consisting essentially of .ltoreq.0.08% carbon, .ltoreq.0.1% acid sol. aluminum, <0.20% manganese, all percentages by weight, the balance iron and unavoidable impurities, is hot rolled from a temperature less than about 1260.degree. C. Preferably, the steel has an r.sub.m value of greater than 2.0 after batch annealing and is produced from a slab reheated to a temperature less than about 1175.degree. C.

Abstract: The thermal flattening of grain oriented silicon steel which is in the semi-processed condition has improved magnetic properties after a stress relief anneal by using a low temperature and high tension flattening anneal. The flattening process is conducted at a temperature between 1000.degree. to 1435.degree. F. (540.degree. to 780.degree. C.) with a tension selected to produce a yield strength/tension ratio from above 5 to about 20 and preferably from 7 to 13. The yield strength of the material will vary depending on the length of the time at peak temperature but are typically from 400 to 4000 psi (29,200 to 292,000 gm/cm.sup.2). The material as thermally flattened will have at least about 10% stress. After a stress relief anneal above about 1450.degree. F. (785.degree. C.), the material has significantly improved core loss compared to conventional thermally flattened material. The material is particularly suited for wound transformer core applications.

Abstract: An apparatus and method for monitoring and maintaining a predetermined width in the gap between a casting nozzle and a casting wheel, wherein the gap is monitored by means of at least one pneumatic gap sensor. The pneumatic gap sensor is mounted on the casting nozzle in proximity to the casting surface and is connected by means of a tube to a regulator and a transducer. The regulator provides a flow of gas through a restictor to the pneumatic gap sensor, and the transducer translates the changes in the gas pressure caused by the proximity of the casting wheel to the pneumatic gap sensor outlet into a signal intelligible to a control device. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces. The apparatus and method enables accurate monitoring of the actual casting gap in a simple and reliable manner resistant to the extreme temperatures and otherwise hostile casting environment.

Abstract: A substantially martensitic stainless steel as cast having good castability, ductility and capability of being hardened to a wide range of hardness, the steel consisting essentially of, in weight percent, up to about 0.08% carbon, about 1.0 to about 4.0% maganese, about 13.0 to about 17.0% chromium, about 1.5 to about 4.0% copper, up to about 0.12% nitrogen, less than about 1.0% silicon, less than about 1.0% molybdenum, less than 1.0% nickel, less than about 0.03% phosphorus, less than about 0.5% sulfur, up to about 0.005% boron, up to 0.5% niobium, vanadium, titanium and/or zirconium and balance essentially iron. The steels have particular utility in the production of cast golf clubs, forged golf clubs, cutlery, boat propellers and other cast, forged and wrought products, including free machining materials.

Abstract: A process of producing regular grain oriented silicon steel having a final thickness of from 7 mils (0.18 mm) to about 18 mils (0.45 mm) including the steps of providing a silicon steel hot band, removing hot band scale, cold rolling to intermediate gauge without an anneal of the hot band, performing an intermediate anneal at a soak temperature of about 1650.degree. F. (900.degree. C.) to about 1700.degree. F. (9300.degree. C.), subjecting said annealed silicon steel to a first stage slow cooling at a rate of about 500.degree. F. (260.degree. C.) to about 1050.degree. F. (585.degree. C.) per minute down to about 1100.degree. F..+-.50.degree. F. (595.degree. C..+-.30.degree. C.), thereafter subjecting said silicon steel to a second stage fast cooling down to from about 600.degree.F. (315.degree. C.) to about 1000.degree. F. (540.degree. C.) at a cooling rate of from about 25.degree. F. (1390.degree. C.) to about 3500.degree. F. (1945.degree. C.

Abstract: Continuously hot dip aluminum coated ferritic chromium alloy steel strip. After the steel has been given a pretreatment to remove surface contaminants, the steel is protected in a hydrogen atmosphere until it is passed into the molten aluminum coating metal. The coating metal readily wets the steel surface to prevent uncoated areas or pin holes in the coating layer.

Abstract: Casting nozzles will provide improved flow conditions with the parameters controlled according to the present invention. The gap relationships between the nozzle slot and exit orifice must be controlled in combination with converging exit passageway to provide a smooth flow without shearing and turbulence in the stream. The nozzle lips are also rounded to improve flow and increase refractory life of the lips of the nozzle. The tundish walls are tapered to provide improve flow for supplying the melt to the nozzle. The nozzle is located about 45.degree. below top dead center for optimum conditions.

Abstract: The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points.

Abstract: The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification.

Abstract: A process of producing high silicon, low melt carbon regular grain electrical silicon steel having a final gauge of from 14 mils (0.35 mm) to about 6 mils (0.15 mm) or less, including the steps of providing a hot band and removing the hot band scale, if needed. The silicon steel is cold rolled to intermediate gauge and subjected to an intermediate anneal at a soak temperature of about 1650.degree. F. (900.degree. C.) to about 1700.degree. F. (930.degree. C.). Thereafter, the silicon steel is cooled in a first stage slow cooling at a rate of about 500.degree. F. (280.degree. C.) to about 1050.degree. F. (585.degree. C.) per minute down to about 1100.degree. F..+-.50.degree. F. (595.degree. C..+-.30.degree. C.). The silicon steel is then subjected to a second stage fast cooling down to from about 600.degree. F. (315.degree. C.) to about 1000.degree. F. (540.degree. C.) at a cooling rate of from about 2500.degree. F. (1390.degree. C.) to about 3500.degree. F. (1945.degree. C.

Abstract: Process and apparatus for forming a plastic coating on a metal strip. A metal strip is cleaned, surface treated, coated with an electrostatically charged plastic powder in an enclosed chamber using a plurality of spray guns positioned on both sides of the strip, inductively heated to above the melting point of the powder, and maintained in an infrared heater until the fused powder is flowed into a coating having a smooth surface and a uniform thickness. Thermoplastic and thermosetting coatings, having thicknesses of at least 10 microns formed using total induction and infrared heating times of less than 60 seconds, can be fabricated without cracking.

Abstract: Apparatus and method for aligning a welding device along the center of a gap defined by confronting edges of at least two workpieces to be joined, wherein relative motion between the welding device and the workpiece gap occurs along a longitudinal axis substantially parallel to the gap such that the proximal edges of the workpieces can be joined by forming a weld seam along the gap during the relative motion. The apparatus preferably includes an imaging system for determining the location of the gap center relative to a predetermined two dimensional coordinate system by monitoring an image of a vision area along the gap downstream of the welding zone. In a preferred embodiment, the imaging system is effectively isolated from the welding zone through use of a high magnification optics system, a shroud structure, an independent light source, and a vectored jet of inert gas supplied to the welding zone.

Abstract: The continuous casting of strip, ribbon and wire is improved by using a free jet nozzle which provides a fluid that follows a rotating substrate surface to the separation point. The nozzle includes an inclined surface having a ratio of its length to the gap between the substrate and the nozzle edge of 5:1 to 15:1. The inclined surface improves the ability of the jet to tangentially follow the substrate in a direction opposite to its rotation to the separation point. This also allows a close positioning of the nozzle to the substrate which serves to provide a back-up mechanical separation means by using the edge of nozzle lip. The nozzle may be rotated from its operating position for cleaning of the substrate and the nozzle.

Abstract: An apparatus and method for regulating the gap between a casting nozzle and a casting wheel in which the gap between the casting nozzle and the casting wheel is monitored by means of at least one sensing element protruding from the face of the casting nozzle. The sensing element is preferably connected to a voltage source and the casting wheel grounded. When the sensing element contacts the casting wheel, an electric circuit is completed. The completion of the circuit can be registered by an indicator, and the presence or absence of a completed circuit indicates the relative position of the casting nozzle to the casting wheel. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces.

Abstract: There is provided a method and device for automatically aligning the proximal edges of two or more appreciably magnetic sheets to be connected along abutting edges. The device preferably includes supports to align the magnetic sheets in substantially planar relationship aligned relative one another with their proximal edges oriented in approximately abutting relationship and generally aligned along a predetermined contiguous seam line. At least one of the sheets is to remain moveable on the supports relative to the other sheets. The alignment device further preferably includes an electromagnetic mechanism for simultaneously creating an effective north pole along the proximal edge of one of the supported sheets, and an effective south pole along the confronting proximal edge of the other sheet. These opposing poles cause a magnetic attraction between the proximal edges of the sheets which automatically pulls and aligns the proximal edges into intimate contact along their length.